ProCore® 648 Aerator

Before starting the machine each day, perform the following daily-check procedures:

• Checking the Engine-Oil Level

• Checking the Hydraulic-Fluid Level

• Cleaning the Engine Screen

• Testing the Safety Interlock System

1. Release the traction bail and engage the parking brake.

2. Use the choke as follows:

   • Before starting a cold engine, move the choke control to the ON position.

   • When starting a warm or hot engine, you may not need to use the choke.

3. Move the throttle lever to the FAST position before starting a cold engine.

4. Turn the ignition key to start. When the engine starts, release the key.

   Important: Do not engage the starter for more than 10 seconds at a time. If the engine fails to start, allow a 30-second cooldown period between attempts. Failure to follow these instructions can burn out the starter motor.

5. After the engine starts, move the choke to the OFF position. If the engine stalls or hesitates, move the choke back to the ON position for a few seconds. Then move the throttle lever to desired setting. Repeat this as required.

1. Move the throttle lever to the SLOW position.

2. Let the engine idle for 60 seconds.

3. Turn the ignition key to the OFF position and remove the key.

4. Close the fuel-shutoff valve before transporting or storing the machine.

   Important: Close the fuel-shutoff valve before transporting the machine on a trailer or storing the machine. Engage the parking brake before transporting the machine. Remove the key as the fuel pump may run and cause the battery to lose charge.

   Caution

   Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.

   Always remove the ignition key and engage the parking brake when leaving the machine unattended, even if just for a few minutes.

1. Start the engine.

2. Disengage the parking brake.

3. Look in the direction of your planned path to ensure that it is clear.

4. Move the traction bail down to drive the machine forward.

   Walk in a forward direction while operating the machine, do not walk and face rearward when operating the machine.

5. Engage the PTO and lower the coring head.

6. Disengage the PTO and raise the coring head.

7. To stop the machine, release the traction bail.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Select the preferred tine for your application.

3. Lay the tine on the tine depth decal (Figure 16) with 1 end lined up with the desired depth of aeration (refer to the tine overlay on the decal).

   

   Figure 16

   1. Aeration depth lever
   2. Overlay on decal

4. Determine which letter setting the other end of the tine lines up with and set the depth control lever to the corresponding letter setting.

Note: As the tine wears, you may be able to reset the depth setting to account for that wear. For instance, if your new tine depth setting has you in the G setting, you can reset to the H setting after 6 mm (1/4 inch) of tine wear.

Use the line marker to align aeration rows (Figure 17).

Figure 17

1. Line marker (storage position)
2. Line marker (alignment position)

Install the service latch before performing service on the coring head or when storing the machine for more than a couple of days.

1. Raise the coring head.

2. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

3. Remove the clip ring securing the service latch in the stowed position (Figure 18).

   

   Figure 18

   1. Service latch in (lowered) storage position

4. Pivot the service latch rearward and insert it onto the coring head pin (Figure 19). Secure the latch with the clip ring.

   

   Figure 19

   1. Service latch in (raised) locked position

The manual depth setting spacers are required only when the TrueCore^® ground following system does not function because of damage to the feedback system (turf guards, tie rod, and actuator assembly) or if you need maximum coring depth.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Remove the lynch pin retaining the spacers and depth pins (Figure 20).

   

   Figure 20

   1. Lynch pin
   2. Spacers and depth pin

3. Position the spacers above or below the bracket to attain the desired coring depth.

   • Thick spacers equate to 19 mm (3/4 inch) increments.

   • Thin spacer equates to 9.5 mm (3/8 inch) depth increment.

   • With all spacers on the top side, the depth setting is 10.7 cm (4-1/4 inches).

4. Remove the locking bolt and nut from the selector switch (Figure 21).

   

   Figure 21

   1. Manual ground following selector switch
   2. Bolt and nut

5. Rotate the switch to the down position to turn off True Core feature.

6. To prevent the setting from accidentally changing, install the locking bolt and nut.

A wide selection of tine holders, turf guards, and tines are available for the machine. Choose the required components per the accessory chart in Attachments and Accessories.

1. Raise the coring head and lock it in position with the service latch.

2. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

3. Mount a tine holder to each tine arm (Figure 22) with 3 bolts (1/2 x 1-1/4 inches). Torque the bolts to 101.6 N∙m (75 ft-lb).

   Note: The bolts are parts in the tine holder kits.

   

   Figure 22

   1. Tine arm
   2. Tine holder

4. Loosely install the turf guards to the turf guard brackets with 4 turf guard clamps and 12 flange nuts (Figure 23). Do not tighten the fasteners.

   Note: The factory ships turf guard clamps and flange nuts secured to the turf guard brackets (Figure 23).

   

   Figure 23

   1. Turf guard
   2. Turf guard clamp

5. Loosely install a tine clamp to each tine holder (Figure 24) with 4 bolts (3/8 x 1-1/2 inches). Do not tighten the bolts.

   

   Figure 24

   1. Tine clamp
   2. Tine

6. Install tines into the #2 and #5 tine holders (Figure 25) Tighten the bolts.

   

   Figure 25

   1. Number 5 tine holder
   2. Number 2 tine holder

7. Check that the tines line up with the center of the gaps in the turf guards (Figure 26). Adjust the turf guards as required and tighten the nuts.

   

   Figure 26

   1. Gaps in the turf guards

8. Install the remaining tines into the #1, 3, 4, and 6 tine holders. Torque all tine holder bolts to 40.6 N∙m (30 ft-lb).

Refer to Installing the Tine Holders, Turf Guards, and Tines for illustrations.

1. Raise the coring head and lock it in position with the service latch.

2. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

3. Loosen the tine holder retaining bolts and remove the old tines.

4. Insert the new tines into the tine holder.

5. Tighten the bolts to the recommended torque level.

6. Repeat this procedure on the remaining arms.

The machine transfers weight from the traction unit to the coring head to help maintain hole depth in various soil structures. However, if the soil structure is firm enough to not allow full aeration depth, the coring head may need additional weight transfer. To increase the down pressure of the weight transfer springs, proceed as follows:

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Loosen the carriage bolt nuts securing the spring brackets to the coring head (Figure 27). Do not remove them.

   

   Figure 27

   1. Weight transfer springs
   2. Spring plate

3. Insert a 1/2 inch ratchet or breaker bar into the square hole in the spring plate (Figure 28).

   

   Figure 28

   1. Square hole in bracket
   2. Rear carriage bolt

4. Hold the ratchet or breaker bar to relieve the tension on the spring plate and remove the rear carriage bolt.

5. Rotate the spring plate until it aligns with the other hole, insert the carriage bolt, and tighten the nuts.

   Note: Rotating the spring plates upward increases the weight transfer.

With the increased weight transfer, it is possible to aerate firm enough ground that the weight transfer begins to lift the rear 2 tires off the ground. This may lead to irregular hole spacing.

If this occurs, you can add an additional weight plate to the rear frame axle tube. Each cast weight adds 28.5 kg (63 lb) to the machine. You can add up to 2 plates. Refer to the Parts Catalog for these part numbers.

Important: Do not tow the machine faster than 1.6 km/h (1 mph) because hydraulic component damage may occur.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Locate the bypass valve between the engine and hydrostatic pump (Figure 29).

3. Using a 5/8 inch wrench, rotate the bypass valve counterclockwise 1 turn. This allows the hydraulic fluid to bypass the pump enabling the wheels to turn (Figure 29).

   

   Figure 29

   1. Bypass valve

   Important: Do not rotate the bypass valve more than 1 turn. This prevents the valve from coming out of the body and causing fluid to run out.

   Important: Do not push/pull the machine more than 30.5 m (100 ft) or faster than 0.6 km/h (1 mph) because hydraulic component damage may occur.

4. Disengage the parking brake before pushing/pulling the machine.

   Important: Do not operate the engine with the bypass valve open for more than 10 to 15 seconds.

5. To operate the machine again, rotate the bypass valve clockwise 1 turn (Figure 29).

   Note: Do not overtighten the bypass valve.

   Note: You must close the bypass valve to drive the machine. Do not try to operate traction system with the bypass valve open.

If the coring head remains in the aerating position (run out of fuel, forget to install service latch for storage, mechanical failure of engine or pump, etc.) the electrical system that controls the hydraulic solenoid coils and the electric clutch disables to prevent unintended movement of the coring head without the intentionally resetting the system.

1. Start the engine.

2. Press the system reset switch (Figure 30).

   The coring head raises and the electrical-control circuit resets.

   Note: If you cannot run the engine, crank the engine with the starter while pressing the system reset switch until the coring head clears the ground.

   

   Figure 30

   1. System reset switch

If the engine fails or you cannot be start it with the coring head lowered and the tines engaged in the soil, perform the following steps:

1. Remove the tine holders from the stomper arms.

2. Open the bypass valve 1 turn.

3. Pull/push the machine to a nearby location to continue service or load onto a trailer.

Important: Do not pull/push machine for more than 30.5 m (100 ft) and no faster than 1.6 km/h (1 mph), because hydraulic damage may occur.

1. Thoroughly wash the machine.

   Use a brush to remove caked-on material.

   Note: Use a garden hose without a nozzle to avoid forcing water past the seals and contaminating bearing grease.

2. Use mild detergent to clean the covers.

   After cleaning, apply a coat of auto wax periodically to maintain the glossy finish of the cover.

3. Inspect the machine for damage, oil leaks, and component and tine wear.

4. Remove, clean, and oil the tines. Spray a light oil mist on coring head bearings (crank and damper links).

Important: Secure the coring head with the service latch if you store the machine for more than a couple of days.

There are tie downs located at the front and rear sides of the machine (Figure 34, Figure 35, and Figure 36).

Note: Use properly-rated DOT-approved straps to tie down the machine.

Figure 34

1. Tie down

Figure 35

1. Tie down

Figure 36

1. Tie down

Important: Use full-width ramps for loading the machine onto a trailer or truck.

1. Load the machine onto the trailer or truck (coring head forward—preferred).

2. Engage the parking brake, shut off the engine, and remove the key.

3. Secure the coring head with the service latch; refer to Supporting the Coring Head with the Service Latch.

4. Close the fuel-shutoff valve; refer to Fuel-Shutoff Valve.

5. At the tie-down points, bind the machine to the trailer or truck with cables, chains, or straps.

Trailer Recommendations

Important: Do not use the Hydroject trailer/tote to trailer this machine.

The machine has no grease fittings to lubricate.

Important: Bearings rarely fail from defects in materials or workmanship. The most common reason for failure is moisture and contamination working its way past the protective seals. Bearings that are greased rely upon regular maintenance to purge harmful debris from the bearing area. Sealed bearings rely on an initial fill of special grease and a robust integral seal to keep contaminants and moisture out of the rolling elements.

The sealed bearings require no lubrication or short term maintenance. This minimizes routine service required and reduces the potential of turf damage due to grease contamination. These sealed bearing packages provide good performance and life under normal use, but periodic inspections of bearing condition and seal integrity should be conducted to avoid downtime. Inspect the bearings seasonally and replace them if they are damaged or worn. Bearings should operate smoothly with no detrimental characteristics such as high heat, noise, looseness, or rust weeping.

Due to the operating conditions these bearing/seal packages are subject to (e.g., sand, turf chemicals, water, impacts, etc.) they are considered normal wear items. Bearings that fail due to causes other than defects in materials or workmanship are typically not covered under warranty.

Note: You can negatively affect the bearings if you do not wash the machine correctly. Do not wash the machine when it is still hot and avoid directing high-pressure or high volume spray at the bearings.

New bearings commonly purge some grease out of the seals on a new machine. This purged grease turns black due to collection of debris, not excessive heat. Wipe this excess grease from the seals after the initial 8 hours. The area around the seal lip may continually appear to be wet; this is not detrimental to bearing life, and keeps the seal lip lubricated.

Oil Type: High-quality, detergent engine oil (API service SJ or higher)

Viscosity: See table below

Figure 43

The engine is shipped with oil in the crankcase; however, check the oil level before and after the engine is first started.

Use high-quality engine oil as described in Engine Oil Specification.

Important: Do not overfill the crankcase with oil because this may cause engine damage.Do not run the engine with oil below the low mark because the engine may be damaged as a result.

Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If it has already been run, allow the oil to drain back down to the sump for at least 10 minutes before checking.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Clean around the oil dipstick (Figure 44) so dirt cannot fall into the filler hole and damage the engine.

   

   Figure 44

   1. Dipstick
   2. Filler tube
   3. Metal end of the dipstick

3. Remove the dipstick, wipe it clean, and install until it is fully seated (Figure 44).

4. Remove the dipstick and check the oil level.

   The oil level should be between the ‘‘F’’ full and ‘‘L’’ low marks on the dipstick (Figure 44).

5. If the oil level is below the ‘‘L’’ low mark, remove the filler tube cap (Figure 44) and add the specified oil until the level reaches the ‘‘F’’ full mark on the dipstick.

6. Install the oil fill cap and dipstick.

Crankcase capacity: approximately 1.9 L (2.0 US qt) with the filter.

1. Start the engine and let it run for 5 minutes. This warms the oil so that it drains better.

2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely, shut off the engine, engage the parking brake, and remove the key.

3. Place a pan below the oil drain. Remove the oil drain plug to allow oil to drain.

4. When the oil has drained completely, replace the plug.

   Note: Dispose of the used oil at a certified recycling center.

5. Place a shallow pan or rag under the filter to catch oil (Figure 45).

   

   Figure 45

   1. Oil filter
   

   Figure 46

   1. Oil filter
   2. Gasket
   3. Adapter

6. Remove the old filter (Figure 45 and Figure 46) and wipe the surface of the filter adapter gasket.

7. Pour new oil of the proper type through the center hole of the filter. Stop pouring when the oil reaches the bottom of the threads.

8. Allow a minute or 2 for the oil to be absorbed by filter material, then pour off the excess oil.

9. Apply a thin coat of new oil to the rubber gasket on the replacement filter.

10. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn.

11. Remove the oil fill cap and slowly pour approximately 80% of the specified amount of oil in through the valve cover.

12. Check the oil level; refer to Checking the Engine-Oil Level.

13. Slowly add additional oil to bring the level to the F (full) mark on the dipstick.

14. Install the oil fill cap and dipstick.

Ensure that the air gap between the center and side electrodes is correct before installing each spark plug. Use a spark-plug wrench for removing and installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. Install new spark plugs if necessary.

Type: Champion RC12YC or equivalent. Air Gap: 0.75 mm (0.03 inch)

Before each use, check and clean the engine screen. Remove any buildup of grass, dirt, or other debris from the engine air intake screen.

Important: Never install a dirty filter if it is removed from the fuel line.

1. Allow the machine to cool down.

2. Close the fuel-shutoff valve (Figure 49).

   

   Figure 49

   1. Fuel filter
   2. Fuel-shutoff valve

3. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 49).

4. Remove the filter from the fuel lines.

5. Install a new filter and move the hose clamps close to the filter (Figure 49).

6. Wipe up any spilled fuel.

7. Open the fuel-shutoff valve (Figure 49).

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Close the fuel-shutoff valve (Figure 49).

3. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter (Figure 49).

4. Pull the fuel line off the fuel filter (Figure 49). Open the fuel-shutoff valve and allow fuel to drain into a fuel can or drain pan.

   Note: Now is the best time to install a new fuel filter because the fuel tank is empty.

5. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Figure 49).

1. Unlatch and open the battery compartment cover.

2. Remove the battery from the battery compartment:

   1. Remove the battery hold down and hold down rods that secure the battery to the tray (Figure 50).

   2. Remove the carriage bolt and nut that secure the negative battery cable (black) to the negative (–) terminal and disconnect the negative cable.

   3. Remove the carriage bolt and nut that secure the positive battery cable (red) to the positive (+) battery terminal and disconnect the positive cable.

3. Clean the top of the battery.

4. Connect a 3 to 4 A battery charger to the battery posts. Charge the battery at a rate of 3 to 4 A for 4 to 8 hours.

5. When the battery is charged, disconnect the charger from the electrical outlet and battery posts.

6. Insert the battery into the tray in the battery compartment as shown in Figure 50.

   

   Figure 50

   1. Battery tray
   2. Battery hold down
   3. Hold down rod
   4. Positive terminal (+)
   5. Negative terminal (–)

7. Connect the positive battery cable (red) to the positive (+) battery terminal with the previously removed carriage bolt and nut; slide the rubber boot over the positive terminal to prevent a possible short from occurring.

8. Connect the negative battery cable (black) to the negative (–) terminal with the previously removed carriage bolt and nut.

9. Coat the cable terminals and battery posts with Grafo 112X skin-over grease (Toro Part No. 505-47).

10. Close and latch the battery compartment cover.

The battery cables must be tight on the terminals to provide good electrical contact.

If corrosion occurs at the terminals, disconnect the cables (negative (–) cable first) and scrape clamps and terminals separately. Connect the cables (positive (+) cable first) and coat the terminals with petroleum jelly.

1. Unlatch and open the battery compartment cover (Figure 51).

   

   Figure 51

   1. Battery compartment

2. Check that the battery-cable clamps are secure and tighten any loose battery-cable clamps hardware.

   Important: Ensure that there is clearance between the battery cables and the speed selector lever. Verify that the speed selector lever does not come within 1 inch (2.5 cm) of either battery cable when it is moved through its entire range of motion. Do not wire tie or tape the negative and positive battery cables together.

3. Check the battery-cable clamps and battery terminals for corrosion; If the terminals are corroded, do the following:

   1. Remove the carriage bolt and nut that secure the negative battery cable (black) to the negative (–) terminal and disconnect the negative cable.

   2. Remove the carriage bolt and nut that secure the positive battery cable (red) to the positive (+) battery terminal and disconnect the positive cable.

   3. Clean the cable clamps and battery terminals.

   4. Connect the positive battery cable (red) to the positive (+) battery terminal with the previously removed carriage bolt and nut; slide the rubber boot over the positive terminal to prevent a possible short from occurring.

   5. Connect the negative battery cable (black) to the negative (–) terminal of the battery with the previously removed carriage bolt and nut.

   6. Coat the cable terminals and battery posts with Grafo 112X skin-over grease (Toro Part No. 505-47).

4. Close and latch the battery compartment cover.

The electrical system is protected by fuses (Figure 52). It requires no maintenance; however, if a fuse blows, check the component/circuit for a malfunction or short.

1. To replace fuses, pull out on the fuse to remove it.

2. Install a new fuse.

Figure 52

1. Fuse block

The Aerator Control Module is a potted electronic device produced in a 1-size-fits-all configuration. The module uses solid-state and mechanical components to monitor and control electrical features required for safe product operation.

Figure 53

1. Aerator control module

The module monitors inputs including head low, head high, transport, aerate, and ground following. The module is divided into inputs and outputs. Inputs and outputs are identified by green LED indicators mounted on the printed circuit board. Power is identified by a red LED indicator.

The start circuit input is energized by 12 VDC. All other inputs are energized when the circuit is closed to ground. Each input has an LED that illuminates when the specific circuit is energized. Use the input LEDs for switch and input circuit troubleshooting.

Output circuits are energized by an appropriate set of input conditions. The 3 outputs include SVL, SVR, and SVQ. Output LEDs monitor relay conditions indicating the presence of voltage at 1 of 3 specific output terminals.

Output circuits do not determine output device integrity, so electrical troubleshooting includes output LED inspection and conventional device and wire harness integrity testing. Measure the impedance of disconnected components, the impedance through the wire harness (disconnected at the ACM), or by temporarily test energizing the specific component.

The ACM does not connect to an external computer or handheld device, cannot be reprogrammed, and does not record intermittent fault troubleshooting data.

The decal on the ACM includes only symbols. The 3 LED output symbols are shown in the output box. All other LEDs are inputs. The chart below identifies the symbols.

Figure 54

1. On/off
2. Output
3. Solenoid valve lower
4. Solenoid valve raise
5. Solenoid valve quick
6. Input
7. Head low
8. Head high
9. Transport (1)
10. Aerate (4)
11. Ground following
12. OK to lower

The following are logical troubleshooting steps for the ACM device:

1. Determine the output fault you are trying to resolve.

2. Move the key switch to the ON position and ensure that the red power LED illuminates.

3. Move all input switches to ensure that all LEDs change state.

4. Position input devices at the appropriate position to achieve the appropriate output.

5. If specific output LED illuminates without appropriate output function, check output harness, connections, and component. Repair as required.

6. If specific output LED does not illuminate, check both fuses.

7. If specific output LED does not illuminate and inputs are in appropriate condition, install new ACM and determine if a fault disappears.

Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

Check to ensure that the air pressure in all tires is 83 kPa (12 psi). Check the tires when they are cold to get the most accurate pressure reading.

Important: Uneven tire pressure can cause uneven coring depth.

Figure 55

1. Valve stem
2. Wheel weight

The machine must not creep when you release the traction bail. If it does, an adjustment is required.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Raise the machine so the front wheel and 1 rear wheel is just off the ground. Place jack stands under machine. Refer to Raising the Machine.

3. Loosen the locknut on the traction adjustment cam (Figure 56).

   

   Figure 56

   1. Traction adjustment cam

4. Start engine and disengage the parking brake.

   Warning

   The engine must be running so that you can make the final adjustment on the traction adjustment cam. This could cause personal injury.

   Keep your hands, feet, face, and other body parts away from the muffler, other hot parts of the engine and any rotating parts.

5. Rotate the cam hex in either direction until the wheels do not rotate.

6. Tighten the locknut securing the adjustment.

7. Shut off the engine.

8. Remove the jack stands and lower the machine to the ground.

9. Test the machine to make sure that it does not creep.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Unlatch and remove the belt cover (Figure 57).

   

   Figure 57

   1. Belt cover

3. Remove the 2 pump shield mounting nuts and remove the shield (Figure 58).

   

   Figure 58

   1. Pump shield

4. Loosen the pump belt idler bolt just enough to allow movement within the adjustment slot (Figure 59).

   

   Figure 59

   1. Idler bolt
   2. Idler pulley

5. Tap the top of the idler pulley and allow the tensioning spring to adjust the belt tension.

   Note: Do not apply more belt tension than the tensioning spring allows as damage to the components may result.

6. Secure the belt idler bolt.

7. Install the pump shield and belt cover.

The drive belts on the machine is durable. However, the normal exposure to UV radiation, ozone, or incidental exposure to chemicals can deteriorate the rubber over time and lead to premature wear or material loss (i.e., chunking).

Inspect the belts yearly for signs of wear, excessive cushion cracks, or large embedded debris. Replace them when needed. A complete belt service kit is available from your authorized Toro distributor.

If the True Core ground following system requires service of any kind (except for replacing the turf guard) or if the tine holders are contacting the turf guards when set in the deepest setting, you may need to reset the depth adjustment tie rod.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Rotate the left turf guard mounting bracket (Figure 60) up until you can insert a locking pin, such as an 8 mm (5/16 inch) drill rod or bolt, between the bracket and the depth setting tube welded to the frame.

   

   Figure 60

   1. Turf guard mounting bracket
   2. Tine depth lever
   3. Out board ball switch
   4. Depth adjustment tie rod
   5. Locking pin

3. Move the tine depth lever (Figure 60) to the H setting (deepest).

4. Disconnect the outboard ball switch (Figure 60) from the wire harness (Head–Low switch).

5. Loosen the jam nuts (left and right) on the depth adjustment tie rod (Figure 60).

6. Use a multi-meter to determine the electrical closure of the ball switch.

7. Rotate the tie rod until the ball switch just closes or makes contact.

8. Secure the left and right jam nuts on the tie rod.

9. Connect the ball switch to the wire harness.

10. Remove the pin from the turf guard bracket and depth setting tube.

Before each use, check the hydraulic lines and hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating.

Note: Keep the areas around the hydraulic system clean from debris buildup.

Alternative fluids: If the specified fluid is not available, you may use other universal tractor hydraulic fluids (UTHF), but use only conventional, petroleum-based products, not synthetics or biodegradable fluids. The specifications must fall within the listed range for all the following material properties and the fluid should meet listed industry standards. Check with your fluid supplier to see if the fluid meets these specifications.

Note: Toro assumes no responsibility for damage caused by improper hydraulic fluid substitution, so use only products from reputable manufacturers who stand behind their recommendation.

Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20 ml (0.67 fl oz) bottles. One bottle is enough for 15 to 22 L (4 to 6 US gallons) of hydraulic fluid. Order part number 44-2500 from your authorized Toro distributor.

Important: Check the level of the hydraulic fluid before the engine is first started and daily thereafter

The hydraulic reservoir is filled at the factory with high-quality hydraulic fluid.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Unlatch and remove the belt cover (Figure 61).

   

   Figure 61

   1. Belt cover
   2. Cover latch

3. Clean the area around the filler neck and the cap of the hydraulic tank (Figure 62). Remove the cap from the filler neck.

   

   Figure 62

   1. Hydraulic-tank cap

4. Remove the dipstick from the filler neck and wipe it with a clean rag. Insert the dipstick into the filler neck; then remove it and check the level of the fluid. The fluid level should be up to the mark on the dipstick (Figure 63).

   

   Figure 63

   1. Dipstick
   2. Full mark

5. If the level is low, add the specified hydraulic fluid to raise the level to the full mark.

6. Install the dipstick and cap onto the filler neck.

Hydraulic reservoir capacity: approximately 6.6 L (1.75 US gallons)

Important: Do not substitute automotive oil filters or severe hydraulic system damage may result.

Note: Removing the return filter drains the entire fluid reservoir.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Place a drain pan under the filters, remove the old filters, and wipe the filter adapter gasket surface clean (Figure 64).

   

   Figure 64

   1. Hydraulic return filter
   2. Hydraulic charge filter

3. Apply a thin coat of hydraulic fluid to the rubber gasket on the replacement filters.

4. Install the replacement hydraulic filters onto the filter adapters. Turn each filter clockwise until the rubber gasket contacts the filter adapter, then tighten each an additional 1/2 turn.

5. Add the specified hydraulic fluid until the fluid level is at the Full mark on the dipstick, refer to Checking the Hydraulic-Fluid Level.

6. Start the engine and let it run for about 2 minutes to purge air from the system. Shut off the engine and remove the key, and check for leaks.

7. Check the fluid level again while the fluid is warm. Add the specified hydraulic fluid to raise the level to the Full mark on the dipstick, if required.

   Note: Do not overfill the hydraulic reservoir with fluid.

The test ports are used to test the pressure in the hydraulic circuits. Contact your authorized Toro distributor for assistance.

• Test Port G 2 (Figure 65) is used to assist in trouble shooting the traction charge circuit.

  

  Figure 65

  1. Test port G2
  2. Test port G1

• Test Port G 1 (Figure 65) is used to assist in trouble shooting the lift circuit pressure.

Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

Check the coring head fasteners, tiller handle fasteners, and wheel lug nuts to ensure that the proper torque is maintained. Fastener torque requirements are listed on the reference service decal located on the coring head.

Figure 66

The coring head side shields should be adjusted so the bottom rides between 25 to 38 mm (1 to 1.5 inches) from the turf while aerating.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Loosen the bolts and nuts securing the side shield to frame (Figure 67).

   

   Figure 67

   1. Side shield

3. Adjust the shield up or down and tighten the nuts.

All turf guards should be replaced if broken or worn to less than 6 mm (1/4 inch) thickness. Broken turf guards can catch and tear turf creating undesirable damage.

Figure 68

1. Turf guard

Thin turf guards can cause the True Core ground following system to be off from the desired depth setting due to both wear and the loss of stiffness.

The hole spacing of the aerator is determined by the ground speed the traction system is set to maintain. The hole spacing is set to within 3 mm (1/8 inch) of the nominal setting at the factory.

In the event the hole spacing is off from the nominal setting more than desired, proceed as follows:

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Unlatch and remove the belt cover (Figure 57).

3. Remove the 2 pump shield mounting nuts and remove the shield (Figure 58).

4. In an open space that is free to aerate (i.e. sample plot), set the aerator spacing lever to the desired hole spacing and make an aeration pass of at least 4.5 m (15 ft).

5. Measure the distance between several holes and divide by the number of holes measured to get your average hole spacing.

   Example: Nominal Hole Spacing Setting of 2 inches:

   21.2 divided by 10 is 2.12, hole spacing is long by .12 inch from nominal (Figure 69).

   

   Figure 69

   1. 21.2 inches (10 holes)

   18.8 divided by 10 is 1.88, hole spacing is short by 0.12 inch from nominal (Figure 70).

   

   Figure 70

   1. 18.8 inches (10 holes)

6. If an adjustment is needed, turn the pump stop bolt (Figure 71) closer to the stop plate to decrease hole spacing or turn the stop bolt away from the stop plate to increase hole spacing.

   

   Figure 71

   1. Pump stop bolt

7. Repeat steps 4 through 6 until spacing is at the nominal setting.

   Note: One complete turn of the stop bolt adjusts the hole spacing approximately 16 mm (5/8 inch).

The coring head timing marks are easily identified by the marks in the casting.

Figure 72

1. Timing marks